Moisture Absorbing Device for Food Packaging

ABSTRACT

A moisture absorbing device, a method of preparing the device, and a method of reducing moisture inside of a food container with the device are disclosed. The device can include a carrier layer and an absorbent layer. The absorbent layer can include a hydrogel composition and, optionally, an adhesive. The device can further include a ventilation layer. The device can further include an attaching layer having an adhesive material on an exposed surface for attaching the device to the food container. The method of preparing the device can include a roll-to-roll assembly process. The method of reducing moisture inside of a food container with the device can include adding food to a first surface of the food container, attaching a moisture absorbing device to a second surface of the food container, and closing the food container.

CROSS-REFERENCE TO RELATED APPLICATIONS

This claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. Provisional Application Ser. No. 63/191,876 filed on May 21, 2021, the content of which is relied upon and incorporated herein by reference in its entirety.

FIELD

The present disclosure generally relates to a moisture absorbing device; and more particularly, to a moisture absorbing device configured for coupling to a food container; and more particularly to a moisture absorbing device configured for coupling to an inside surface of a food container, and a method of using the device to reduce the humidity and moisture inside of a food container containing food being transported inside the food container.

BACKGROUND

When warm or hot food, including crispy or crunchy food, is delivered to a consumer, or taken away from a restaurant by the consumer, the recently cooked food produces steam (water vapor) that can increase the humidity and atmospheric moisture inside of the food container. By the time the consumer is ready to eat the food, even when the period since cooking is brief, the texture and taste of the food will likely have been modified by the moisture inside the food container. Fried foods, including French fries, for example, are often soggy instead of crispy after being transported from a restaurant to the consumers destination. Consumers, therefore, may order specific food items from a menu and not others because certain foods are not appetizing after transport/delivery. Cold food and produce (e.g., berries, lettuce, microgreens) can also create moisture inside of a food container. For example, droplets of condensation can form on the interior surface and then effect the texture and/or taste of food items inside the container. Accordingly, there is a need for an improved method and device for reducing the humidity inside a food container to keep food appetizing after it has been delivered from the restaurant to the location where the consumer will eat it.

SUMMARY

In various embodiments, a moisture absorbing device for reducing moisture inside of a food container during use is provided. The device can comprise: a carrier layer having a bottom surface and a top surface separated from the bottom surface by a first spaced distance, wherein the first spaced distance defines a thickness of the carrier layer; and an absorbent layer having a bottom surface in continuous contact with the top surface of the carrier layer, and a top surface separated from the bottom surface by a second spaced distance, wherein the second spaced distance defines a thickness of the absorbent layer; and wherein the absorbent layer comprises a hydrogel composition.

In some embodiments, the absorbent layer further comprises an adhesive.

In some embodiments, the moisture absorbing device further comprises a ventilation layer having a bottom surface in non-continuous contact with the top surface of the absorbent layer and a top surface separated by a third spaced distance from the bottom surface.

In some embodiments, the moisture absorbing device can further comprise an attaching layer having a bottom surface in non-continuous contact with the top surface of the ventilation layer and a top surface separated by a fourth spaced distance from the bottom surface, wherein the fourth spaced distance defines a thickness of the attaching layer; wherein the attaching layer comprises an adhesive material on the top surface for attaching the device to a surface of the food container.

In some embodiments, the moisture absorbing device can further comprise a removable sheet covering the top surface of the attaching layer, wherein the adhesive material on the top surface is exposed upon removal of the removeable sheet.

In some embodiments, the moisture absorbing device can further comprise a removeable liner covering the bottom surface of the carrier layer, wherein the bottom surface of the carrier layer is exposed to the moisture inside of the food container upon removal of the removeable liner.

In some embodiments, the hydrogel composition can comprise a polyacrylic acid, polyacrylamide, polyvinyl alcohol, ethylene, maleic anhydride copolymers, polyvinyl ethers, methyl cellulose, carboxymethyl cellulose, hydroxypropylcellulose, polyvinylmorpholinone, or a salt thereof.

In some embodiments, the hydrogel composition can comprise a polyacrylic acid or an alkali metal salt of a polyacrylic acid.

In some embodiments, the hydrogel composition can comprise a polyvinyl alcohol or an alkali metal salt of a polyvinyl alcohol.

In some embodiments, the hydrogel composition is present in an amount from about 5 to about 98 weight percent based on total weight of the absorbent layer.

In some embodiments, the hydrogel composition can absorb at least 10 times its weight in moisture.

In some embodiments, the ventilation layer comprises a fluted structure having a first plurality of open channels extending along the top surface of the absorbent layer.

In some embodiments, the ventilation layer comprises a fluted structure having a first plurality of open channels extending along the top surface of the absorbent layer and a second plurality of open channels extending along the bottom surface of the attaching layer.

In some embodiments, the ventilation layer is comprised of corrugated paper, paperboard, cardboard, and processed into a fluted, wavy, convoluted, accordion, or honeycomb design.

In some embodiments, the carrier layer is comprised of a porous material, a fibrous textile, a non-woven fabric, a tight-weaved material, or a combination thereof; and wherein the carrier layer is configured to allow moisture-containing air from the food container to reach the absorbent layer.

In some embodiments, the removable sheet is comprised of an acrylic-based pressure-sensitive adhesive.

In various embodiments, a method of reducing the moisture inside of a food container containing food is provided. In some embodiments, the food is cooked food having a temperature above room temperature. In some embodiments, the method comprises: adding the food to a first surface of the food container; attaching a moisture absorbing device to a second surface of the food container, the device comprising: a carrier layer having a bottom surface and a top surface separated from the bottom surface by a first spaced distance, wherein the first spaced distance defines a thickness of the carrier layer; and an absorbent layer having a bottom surface in continuous contact with the top surface of the carrier layer, and a top surface separated from the bottom surface by a second spaced distance, wherein the second spaced distance defines a thickness of the absorbent layer; wherein the absorbent layer comprises a hydrogel composition; and closing the food container.

In some embodiments, the absorbent layer in the device of the method further comprises an adhesive; and the method comprises a roll-to-roll assembly of the device, including: providing the carrier layer, depositing the absorbent layer onto the top surface of the carrier layer; and adhering the top surface of the absorbent layer to an interior surface of a food container.

In some embodiments, the device of the method further comprises a ventilation layer having a bottom surface in non-continuous contact with the top surface of the absorbent layer and a top surface separated by a third spaced distance from the bottom surface.

In some embodiments, the device in the method further comprises: an attaching layer having a bottom surface in contact with the top surface of the ventilation layer and a top surface separated by a fourth spaced distance from the bottom surface, wherein the fourth spaced distance defines a thickness of the attaching layer; wherein the attaching layer comprises an adhesive material on the top surface for attaching the device to a surface of the food container; and a removable sheet covering the top surface of the attaching layer, wherein the adhesive material on the top surface is exposed upon removal of the removeable sheet.

In some embodiments, the method further comprises, prior to attaching the moisture absorbing device to the second surface of the food container, removing the removable sheet from the attaching layer.

In some embodiments, the device in the method further comprises a removeable liner covering the bottom surface of the carrier layer, wherein the bottom surface of the carrier layer is exposed to the moisture inside of the food container upon removal of the removeable liner.

In some embodiments, the method further comprises, prior to closing the food container, removing the removeable liner from the carrier layer.

In various embodiments, a method of preparing a moisture absorbing device, comprising: a carrier layer having a bottom surface and a top surface separated from the bottom surface by a first spaced distance, wherein the first spaced distance defines a thickness of the carrier layer; and an absorbent layer having a bottom surface in continuous contact with the top surface of the carrier layer, and a top surface separated from the bottom surface by a second spaced distance, wherein the second spaced distance defines a thickness of the absorbent layer; and wherein the absorbent layer comprises a hydrogel composition.

In some embodiments, the absorbent layer in the device of the method further comprises an adhesive; and the method comprises: a roll-to-roll assembly of the device, including: providing the carrier layer, depositing the absorbent layer onto the top surface of the carrier layer; and joining the top surface of the absorbent layer to an interior surface of a food container.

In some embodiments, the device of the method further comprises a ventilation layer having a bottom surface in non-continuous contact with the top surface of the absorbent layer and a top surface separated by a third spaced distance from the bottom surface; and an attaching layer having a bottom surface in non-continuous contact with the top surface of the ventilation layer and an top surface separated by a fourth spaced distance from the bottom surface, wherein the fourth spaced distance defines a thickness of the attaching layer; wherein the attaching layer comprises an adhesive material on the top surface for attaching the device to a surface of the food container; and the method comprising a roll-to-roll assembly of the device, including: providing the carrier layer, depositing the absorbent layer onto the top surface of the carrier layer; adhering the bottom surface of the ventilation layer to the top surface of the absorbent layer; adhering the bottom surface of the attaching layer to the top surface of the ventilation layer; and adhering the top surface of the attaching layer to an interior surface of a food container.

It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein and, together with the description, explain the principles and operations of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the present embodiments and the advantages and features thereof will be more readily understood by reference to the following detailed description, appended claims, and accompanying drawings, wherein:

FIG. 1 is a cross-sectional view of a moisture absorbing device, taken along the K-K′ line in FIG. 3, in accordance with embodiments described herein;

FIG. 2 is a cross-sectional view of the moisture absorbing device in FIG. 1 in a modified form;

FIG. 3 is a perspective view of the moisture absorbing device, in accordance with embodiments described herein;

FIG. 4 is a perspective view of the moisture absorbing device in FIG. 3 after attachment to a food container, in accordance with embodiments described herein; and

FIG. 5 is a cross-sectional view of the moisture absorbing device in FIG. 4 after attachment to a food container.

The drawings are not necessarily to scale, and certain features and certain views of the drawings may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.

DETAILED DESCRIPTION

Reference will now be made in detail to the exemplary embodiment(s), examples of which is/are illustrated in the examples. Before describing the exemplary embodiments, it is noted the embodiments reside primarily in combinations of components and procedures related to the moisture absorbing device. Accordingly, the composition and method components have been represented where appropriate, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

The specific details of the various embodiments described herein are used for demonstration purposes only, and no unnecessary limitation or inferences are to be understood therefrom.

In various embodiments, a moisture absorbing device and method of using the device to reduce the moisture present inside of a food container are provided. The device is configured to be attached to various food containers, including disposable food containers. The disposable food containers can be paper, paperboard, corrugated fiberboard, plastic- or wax-coated paper, wood, thermoforming (plastics), molded pulp, chip board, or other materials. Examples of disposable food containers include corrugated cardboard pizza boxes, foam (e.g., Styrofoam) clamshells, paperboard clamshells, insulated paper containers, or other existing food containers currently available for packaging food for delivery. In some embodiments, the disposable food container is produced using in-line machinery.

In various embodiments, as shown in FIGS. 1-5, the moisture absorbing device 100 is configured for coupling to the food container C. In some embodiments, consistent with the cross-sectional views in FIGS. 1 and 2, the moisture absorbing device 100 comprises a multilayer internal construction, in which adjacent layers of a plurality of layers are sequentially positioned, one on top of the next, such that the device extends from the bottom surface 104 to the top surface 126 of the device. In this context, the term “top surface” refers to the surface of the moisture absorbing device 100 that is configured to contact and attach to the upper interior surface D of the food container C, and the term “bottom surface” refers to the surface of the moisture absorbing device 100 that faces the lower interior surface B of the food container C and the food F. In various embodiments, the multilayer construction of the moisture absorbing device 100 includes the carrier layer 110 and the absorbent layer 115. In some embodiments, the multilayer construction of the moisture absorbing device 100 includes the carrier layer 110, the absorbent layer 115, and the ventilation layer 120. In some embodiments, the moisture absorbing device 100 includes further layers.

The moisture absorbing device 100 can have any suitable three-dimensional shape, including, for example, shapes that are generally cuboid, rectangular cuboid, cylinder, hemisphere, prism, etc. In such embodiments, the moisture absorbing device 100 has a predetermined height H, as shown in FIG. 2. In this context, the term “generally” is used as a qualifier because certain portions of the device may not fit within the specific shape. For example, if the device is packaged as a pouch, then it could have a crimped boundary portion; and, therefore, the majority (e.g., 75%, 80%, 85%, 90%, 95%, 98%, etc.) of the device would have the stated shape, but the edges in the boundary portion could be tapered and crimped to seal the pouch. In some embodiments, consistent with the perspective views in FIGS. 3 and 4, the moisture absorbing device 100 comprises a generally cuboid or rectangular cuboid shape. In such embodiments, the carrier layer 110, the absorbent layer 115, and any additional layers have a complementary generally cuboid or rectangular cuboid shape, and the ventilation layer 120 has a shape configured to fill a generally cuboid or rectangular cuboid void, as shown in FIGS. 1 and 2.

The moisture absorbing device 100 can have any suitable length L and width W. In some embodiments, the length and width are identical (e.g., square); in other embodiments, the length and width are different (e.g., rectangle). When the length and width are different, as shown in FIG. 3, the width extends laterally about the x-axis and the length extends longitudinally about the y-axis. The height extends along the z-axis. The cross-sectional views in FIGS. 1 and 2 show the width W. In some embodiments, the length L and width W can span from about 1 cm to about 50 cm, or from about 2 cm to about 40 cm, or from about 3 cm to about 30 cm, or from about 4 cm to about 20 cm, or from about 5 cm to about 10 cm, etc.

In some embodiments, the moisture absorbing device 100 has a substantially flat and planar shape so that it can be applied in a manner similar to how a label would be attached to a food container. For example, in some embodiments, the moisture absorbing device 100 can be rolled onto the food container C during a manufacturing step in, for example, a roll-to-roll fabrication process. In such embodiments, the moisture absorbing device 100 has a predetermined height H, as shown in FIG. 2, but the height can span a short distance (e.g., 1-10 mm, including 2 mm, 3 mm, 4 mm, etc.) and therefore appear to be a flat or coplanar device from certain perspectives. In various embodiments, the height H of the moisture absorbing device 100, along with the internal space of the food container, will determine the distance between food contained inside the food container and the moisture absorbing device 100. During use, the distance between the device and the food is preferably at least 1 cm, or in a range of between about 1 cm and about 10 cm, including any subranges, such as between about 2 cm and about 5 cm, etc. A predetermined distance between the device and the food allows the moisture released from the food (e.g., steam) to be efficiently captured by the device.

In some embodiments, during use, the carrier layer 110 comprises a bottom surface 109 that faces the food F located on the lower interior surface B of the food container C, and a top surface 111 that faces the upper interior surface D of the food container C, as shown in FIGS. 1-5. In some embodiments, the carrier layer 110 provides a physical barrier between the absorbent layer 115 and the food F. In such embodiments, the carrier layer 110 separates the food F from the absorbent layer 115. In some embodiments, the carrier layer 110 is comprised of a material that can absorb one or more components of the absorbent layer 115, in addition to moisture present in the food container. In such embodiments, if one or more components in the absorbent layer 115 were to leak, the carrier layer 110 would absorb those components and prevent the same from contacting the food F.

In some embodiments, the carrier layer 110 comprises a water vapor transmission rate that is efficient enough to permit the steam S emanating from the food F, as shown in FIG. 5, to penetrate through to the absorbent layer 115. In some embodiments, the carrier layer 110 comprises a porous material, a fibrous textile, a non-woven fabric, a tight-weaved material, or a combination thereof, which permits the steam S emanating from the food F to penetrate from the atmosphere inside the food container C to the absorbent layer 115. In some embodiments, the carrier layer 110 comprises a fibrous textile, non-woven fabric, tight weaved material, porous material, or a combination thereof. In some embodiments, the fibrous textile, non-woven fabric, and/or porous material comprises one or more vents, slots, and/or channels to assist in the flow of air from the container to the absorbent layer. In some embodiments, the carrier layer 110 comprises one or more vents, slots, and/or channels to assist in the flow of air from the container to the absorbent layer 115.

In some embodiments, the carrier layer 110 comprises a top surface 111 that faces the absorbent layer 115. In some embodiments, the top surface 111 is in contact with a bottom surface 114 of the absorbent layer 115. In some embodiments, the carrier layer 110 serves as a base upon which the absorbent layer 115 may be carried, casted, and/or established on. In such embodiments, the absorbent layer 115 can be deposited on the carrier layer 110, which will carry the absorbent layer 115 during the manufacturing process. In such embodiments, the carrier layer 110 and the absorbent layer 115 are fused together through physical and/or chemical bonding. In some embodiments, the physical and/or chemical bonding is optionally facilitated, catalyzed, or created by an adhesive material.

In some embodiments, the absorbent layer 115 is positioned between the carrier layer 110 and the ventilation layer 120. In some embodiments, the absorbent layer 115 comprises one or more materials or components that are capable of absorbing moisture, whether in a liquid or gas state, or in the form of a droplet, vapor, steam, etc. The one or more absorbing materials can absorb the moisture by physical means, chemical means, or a combination thereof. Suitable absorbent materials for the absorbent layer 115 include organic materials, such as fibrous materials and polymeric materials, and inorganic materials. Organic fibrous materials include woody or non-woody pulp such as cotton, combined cotton, rayon, recycled paper, and pulp fluff. Organic polymeric materials include superabsorbent materials. In this context, a “superabsorbent” material refers to a water-swellable, water-soluble organic or inorganic material capable, under favorable conditions, of absorbing at least about 10 times its weight, or at least about 20 times its weight, in an aqueous solution containing 0.9 weight percent sodium chloride. Suitable organic superabsorbent materials include natural materials such as guar gum, agar, gelatin, collagen, pectin and the like, and synthetic materials, such as hydrogel polymers.

In some embodiments, the absorbent layer 115 comprises a hydrogel composition that is capable of absorbing moisture, whether in a liquid or gas state, or in the form of a droplet, vapor, steam, etc. In such embodiments, the hydrogel composition can include, for example, one or more of the following: alkali metal salts of polyacrylic acids, polyacrylamides, polyvinyl alcohol, ethylene, maleic anhydride copolymers, polyvinyl ethers, cellulose, okara cellulose, methyl cellulose, carboxymethyl cellulose, hydroxypropylcellulose, polyvinylmorpholinone, and polymers and copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides, polyvinylpyrridine, and the like. Other suitable superabsorbent materials include hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, hyaluronic acid, chitosan, alginate, and isobutylene maleic anhydride polymers and mixtures thereof.

In some embodiments, the hydrogel composition comprises polymers that are crosslinked to render the materials substantially water insoluble. In such embodiments, the crosslinking may be accomplished, for example, by irradiation or by covalent, ionic, van der Waals, or hydrogen bonding. The superabsorbent materials may be in any form suitable for use in the absorbent layer 115, including, for example, particles, fibers, flakes, spheres, etc. In some embodiments, the absorbent layer 115 comprises the superabsorbent material in an amount from about 5 to about 98 weight percent based on total weight of the absorbent layer, whereby the stated range includes any intermediate endpoints and subranges (e.g., from about 10 to about 95 weight percent, about 15 to about 90 weight percent, about 20 to about 85 weight percent, etc.).

In some embodiments, the absorbent layer 115 comprises a hydrogel composition that is stable enough to be dried during the manufacturing and/or assembly process for the moisture absorbing device 100. In such embodiments, for example, the absorbent layer 115 or the moisture absorbing device 100 may be inserted into an oven to fully remove any moisture residing in the hydrogel, the absorbent layer 115, the carrier layer 110, and/or the ventilation layer 120.

In some embodiments, the absorbent layer 115 further comprises one or more absorption enhancers that increase the rate of condensation (droplet formation) and/or moisture absorption in the absorbent layer 115 or in the superabsorbent hydrogel contained therein. In some embodiments, the absorption enhancer is a salt or salt mixture. In some embodiments, the salt is calcium chloride (CaCl₂)) or the like. In various embodiments, the combination of the one or more absorbing materials and the absorption enhancer allows the device to absorb and hold substantially more moisture (e.g., water) than if the absorbent layer 115 were comprised only of a fabric or a similar textile-based absorbent material.

In some embodiments, the absorbent layer 115 further comprises one or more adhesives configured to attach the moisture absorbing device 100 to an inside surface of a food container. In such embodiments, the adhesive can be a synthetic rubber-based or water-borne acrylic-based pressure-sensitive adhesive (PSA) material. In some embodiments, the adhesive is a hot-melt adhesive configured for application via a hot glue gun or the like. Existing hot-melt adhesives that can be utilized include, for example, tackifying resins, waxes, plasticizers, fugitive glues, etc.

In some embodiments, absorbent layer 115 comprises a sheet that is removably attached to and configured to cover the top surface 116. The removable sheet be any suitable material, whereby the suitability is based on its ability to be readily released from the absorbent layer 115 while allowing the absorbent layer 115 to maintain its ability to be attached to a food container. For example, in some embodiments, the absorbent layer 115 comprises an adhesive or other fastening material that can facilitate the coupling of the moisture absorbing device 100 to a food container, but the removable sheet must be non-reactive and allow the absorbent layer 115 to maintain its adhesive and fastening properties. In some embodiments, the absorbent layer 115 includes a synthetic rubber-based or water-borne acrylic-based pressure-sensitive adhesive (PSA) material.

In some embodiments, the moisture absorbing device 100 further comprises the ventilation layer 120. In such embodiments, the ventilation layer 120 is secured to the top surface 116 of the absorbent layer 115. In some embodiments, the ventilation layer 120 is in continuous contact with the top surface 116 of the absorbent layer 115. In other embodiments, the ventilation layer 120 is in non-continuous contact with the top surface 116 of the absorbent layer 115. In some embodiments, ventilation layer 120 comprises a fluted, wavy, convoluted, accordion, or honeycomb design that is designed to increase the exposed surface area of the top surface 116 of the absorbent layer 115. In some embodiments, as shown in FIGS. 1 and 2, for example, the ventilation layer 120 comprises a fluted structure. In such embodiments, the fluted structure comprises a plurality of lower channels, including channels 119 a, 119 b, 119 c, along the surface of top surface 116 of the absorbent layer 115. The plurality of lower channels provides access to the absorbent layer 115, and therefore increases the surface area of the absorbent layer 115 that is exposed to water vapors during use of the moisture absorbing device 100.

The ventilation layer 120 can be comprised of any suitable material. For example, in some embodiments, the ventilation layer 120 is corrugated paper, paperboard, cardboard, or a similar material that can be processed into a fluted, wavy, convoluted, accordion, or honeycomb design. In some embodiments, the ventilation layer 120 comprises a single layer of material, and in other embodiments, the ventilation layer 120 comprises a plurality of material layers. Single face corrugated paper, for example, generally comprises a medium layer that includes the three-dimensional design (fluted, wavy, etc.), and a liner material having flat surfaces attached to the same. In embodiments comprising a single layer of material, the medium layer of the corrugated paper can be utilized as the ventilation layer 120; i.e., without the liner layer.

In some embodiments, the moisture absorbing device 100 further comprises an attaching layer 125, as shown in FIGS. 1 and 2. In such embodiments, the attaching layer 125 comprises a top surface 126 and a bottom surface 124. In such embodiments, the attaching layer 125 is configured to attach the moisture absorbing device 100 to an inside surface of a food container. The illustrations in FIGS. 4 and 5, for example, show the moisture absorbing device 100 attached to the upper surface D of the food container C. The moisture absorbing device 100 can be attached to the food container C using any suitable means, including physical attachment and/or chemical attachment. In this context, physical attachment includes coupling the device to the container without an adhesive. For example, if the device has a rectangular shape, two or more corners thereof can be slid into slots present in a surface of the food container C.

As shown in FIG. 1, the attaching layer 125 can be coupled to the ventilation layer 120. In such embodiments, the ventilation layer 120 is positioned between the absorbent layer 115 and the attaching layer 125. In such embodiments, the fluted structure of the ventilation layer 120 comprises a plurality of upper channels, including channels 121 a, 121 b, 121 c, along the bottom surface 124 of the attaching layer 125.

In some embodiments, the attaching layer 125 comprises a sheet that is removably attached to and configured to cover the top surface 126. The removable sheet be any suitable material, whereby the suitability is based on its ability to be readily released from the attaching layer 125 while allowing the attaching layer 125 to maintain its ability to be attached to a food container. For example, in some embodiments, the attaching layer 125 comprises an adhesive or other fastening material that can facilitate the coupling of the moisture absorbing device 100 to a food container, but the removable sheet must be non-reactive and allow the attaching layer 125 to maintain its adhesive and fastening properties. In some embodiments, the attaching layer 125 includes a synthetic rubber-based or water-borne acrylic-based pressure-sensitive adhesive (PSA) material. In some embodiments, the adhesive is a hot-melt adhesive configured for application via a hot glue gun or the like. Existing hot-melt adhesives that can be utilized include, for example, tackifying resins, waxes, plasticizers, fugitive glues, etc.

In some embodiments, the moisture absorbing device 100 further comprises a removable liner 105, as shown in FIG. 1, which is adhered to and covers the bottom surface 109 of the carrier layer 110. FIG. 2 shows the moisture absorbing device 100 with the liner 105 removed and top surface 111 of the carrier layer 110 exposed. During use, as shown in the difference between FIGS. 4 and 5, the liner 105 is removed and the bottom surface 109 of the carrier layer 110 is exposed and accessible to any moisture (e.g., steam S) in the food container C, thus activating the moisture absorbing device 100. The liner 105 can be any suitable material, whereby the suitability is based on its ability to be readily released from the carrier layer 110.

During use, the moisture absorbing device described herein is configured to remove moisture from the inside space of a food container. The function of absorbing moisture in this context must be initiated quickly and last for the amount of time that is typical for food delivery or take out, which ranges about from 5 to 60 minutes, or from about 10 to 45 minutes, or from about 15 to 30 minutes. During such a time period, the moisture absorbing device functions by absorbing the moisture present in the atmosphere, which in turn results in more appetizing food (e.g., dried or fried hot foods).

The adjacent layers of the multilayer construction of the moisture absorbing device 100 can be assembled using any suitable method, including, for example, double-sided tape, glue or another liquid adhesive, or an aerosol adhesive. The moisture absorbing device 100 can be manufactured manually or mechanically. In some embodiments, for example, the moisture absorbing device 100 can be assembled in a roll-to-roll process. In some embodiments, the assembly of the moisture absorbing device 100 can be coupled to the manufacturing process of a food container. In such embodiments, the food container can be manufactured using mechanical systems and then sent to a machine that uses a roll-to-roll process to adhere the device to the food container. In the roll-to-roll process, the moisture absorbing device 100 may be applied to a food container with or without adhesive. In some embodiments, the moisture absorbing device 100 comprises an adhesive material to join the device to a food container. In other embodiments, the adhesive material is absent from the moisture absorbing device 100 and the process utilizes roll-to-roll machines that are configured to apply an adhesive layer to the device before joining it to a food container. And in further embodiments, the moisture absorbing device 100 is joined to a food container without adhesive. In such embodiments, the device is joined to the food container mechanically. For example, the lid of the food container can include slits or tabs that are configured to receive the moisture absorbing device 100.

The following examples are provided to aid in the understanding of the present disclosure, the true scope of which is set forth in the appended claims. One of skill in the art would appreciate that modifications can be made in the procedures set forth without departing from the spirit of the disclosure.

Example 1. A moisture absorbing device comprising an absorbent layer, a carrier layer, a ventilation layer, and an attaching layer, configured in a manner consistent with the device shown in FIG. 2. The absorbent layer comprises a hydrogel composition and a calcium chloride absorption enhancer. The hydrogel composition comprises an alkali metal salt of polyvinyl alcohol. The carrier layer comprises a porous fabric upon which the absorbent layer is deposited on. The device spans about 10 cm in length, about 5 cm in width, and about 3 mm in height. The device was coupled to a first food container using adhesive contained on the top surface of the attaching layer. The first food container included hot food, including French fries, that was purchased from a restaurant and then taken away. A second food container containing the same food was also purchased from the restaurant for use as a control. The second food container did not include the moisture absorbing device. The food inside of the first and second food containers was stored for approximately 30 minutes and then tested. The food contained in the first food container was deemed fresher and crispier than the food contained in the second food container. The food in the second food container was somewhat soggy. The food in the first food container was not soggy. The food in the first food container was more appetizing due to the fresh and crispy nature of the food after the approximately 30 minutes of travel time.

Example 2. A moisture absorbing device comprising a carrier layer and an absorbent layer which is a modified version of the device shown in FIG. 2, whereby the modification includes the absence of the ventilation layer and the absence of the attaching layer. In this example, the absorbent layer comprises a hydrogel composition and an adhesive material. The combination of the hydrogel and the adhesive provides a dual functionality for the absorbent layer. More specifically, the hydrogel composition is capable of absorbing moisture from the atmosphere inside of a food container having food contained therein, and the adhesive is capable of attaching the device to the food container. In this example, the top surface 116 of the adhesive layer 115 is joined directly to the inside surface D of the food container C.

A recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. As will be understood by one skilled in the art, ranges disclosed herein encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art, language such as “up to,” “at least,” “greater than,” “less than,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, a component provided in 1-3 grams refers to the component being provided in 1, 2, or 3 grams.

As used herein, the use of examples, or exemplary language (e.g., “such as”), is intended to illuminate the embodiments and does not pose a limitation on the scope of the claims unless otherwise stated. No language in the specification should be construed as indicating any non-claimed element as essential.

As used herein, the terms “about” and “substantially” will be understood by persons of ordinary skill in the art and will vary to some extent depending upon the context in which it is used. If there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, “about” and “substantially” will mean up to plus or minus 10% of the particular term.

Exemplary embodiments of the methods are described above in detail. The methods are not limited to the specific embodiments described herein, but rather, steps of the method may be utilized independently and separately from other steps described herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.

This written description uses examples to disclose the present embodiments, including the best mode, and also to enable any person skilled in the art to practice the present embodiments, including making and using the moisture absorbing device or performing any methods. The patentable scope of the present embodiments is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have elements that do not differ from the literal language of the claims, or if they include equivalent elements with insubstantial differences from the literal language of the claims. 

I/We claim:
 1. A moisture absorbing device for reducing moisture inside of a food container during use, the device comprising: a carrier layer having a first surface and a second surface separated from the first surface by a first spaced distance, wherein the first spaced distance defines a thickness of the carrier layer; and an absorbent layer having a third surface in continuous contact with the second surface of the carrier layer, and a fourth surface separated from the third surface by a second spaced distance, wherein the second spaced distance defines a thickness of the absorbent layer; wherein the absorbent layer comprises a hydrogel composition.
 2. The moisture absorbing device of claim 1, wherein the absorbent layer further comprises an adhesive.
 3. The moisture absorbing device of claim 1, further comprising a ventilation layer having a fifth surface in non-continuous contact with the fourth surface of the absorbent layer and a sixth surface separated by a third spaced distance from the fifth surface.
 4. The moisture absorbing device of claim 3, further comprising an attaching layer having a seventh surface in non-continuous contact with the sixth surface of the ventilation layer and an eighth surface separated by a fourth spaced distance from the seventh surface, wherein the fourth spaced distance defines a thickness of the attaching layer; wherein the attaching layer comprises an adhesive material on the eighth surface for attaching the device to a surface of the food container.
 5. The moisture absorbing device of claim 4, further comprising a removable sheet covering the eighth surface of the attaching layer, wherein the adhesive material on the eight surface is exposed upon removal of the removeable sheet.
 6. The moisture absorbing device of claim 1, further comprising a removeable liner covering the first surface of the carrier layer, wherein the first surface of the carrier layer is exposed to the moisture inside of the food container upon removal of the removeable liner.
 7. The moisture absorbing device of claim 1, wherein the hydrogel composition comprises a polyacrylic acid, polyacrylamide, polyvinyl alcohol, ethylene, maleic anhydride copolymers, polyvinyl ethers, methyl cellulose, carboxymethyl cellulose, hydroxypropylcellulose, polyvinylmorpholinone, or a salt thereof.
 8. The moisture absorbing device of claim 7, wherein the hydrogel composition comprises a polyvinyl alcohol or an alkali metal salt of a polyvinyl alcohol; or wherein the hydrogel composition comprises a polyacrylic acid or an alkali metal salt of a polyacrylic acid.
 9. The moisture absorbing device of claim 8, wherein the hydrogel composition is present in an amount from about 5 to about 98 weight percent based on total weight of the absorbent layer.
 10. The moisture absorbing device of claim 1, wherein the ventilation layer comprises a fluted structure having a first plurality of open channels extending along the second surface of the absorbent layer.
 11. The moisture absorbing device of claim 3, wherein the ventilation layer comprises a fluted structure having a first plurality of open channels extending along the second surface of the absorbent layer and a second plurality of open channels extending along the seventh surface of the attaching layer.
 12. The moisture absorbing device of claim 3, wherein the ventilation layer is comprised of corrugated paper, paperboard, cardboard, and processed into a fluted, wavy, convoluted, accordion, or honeycomb design.
 13. The moisture absorbing device of claim 1, wherein the carrier layer is comprised of a porous material, a fibrous textile, a non-woven fabric, a tight-weaved material, or a combination thereof; and wherein the carrier layer is configured to allow moisture-containing air from the food container to reach the absorbent layer.
 14. The moisture absorbing device of claim 5, wherein the removable sheet is comprised of an acrylic-based pressure-sensitive adhesive.
 15. A method of reducing the moisture inside of a food container containing cooked food having a temperature above room temperature, comprising: adding the cooked food to a first surface of the food container; attaching a moisture absorbing device to a second surface of the food container, the device comprising: a carrier layer having a first surface and a second surface separated from the first surface by a first spaced distance, wherein the first spaced distance defines a thickness of the carrier layer; and an absorbent layer having a third surface in continuous contact with the second surface of the carrier layer, and a fourth surface separated from the third surface by a second spaced distance, wherein the second spaced distance defines a thickness of the absorbent layer; wherein the absorbent layer comprises a hydrogel composition; and closing the food container.
 16. The method of claim 15, wherein the device further comprises: a ventilation layer having a fifth surface in non-continuous contact with the fourth surface of the absorbent layer and a sixth surface separated by a third spaced distance from the fifth surface.
 17. The method of claim 16, wherein the device further comprises: an attaching layer having a seventh surface in non-continuous contact with the sixth surface of the ventilation layer and an eighth surface separated by a fourth spaced distance from the seventh surface, wherein the fourth spaced distance defines a thickness of the attaching layer; wherein the attaching layer comprises an adhesive material on the eighth surface for attaching the device to a surface of the food container; and a removable sheet covering the eighth surface of the attaching layer, wherein the adhesive material on the eight surface is exposed upon removal of the removeable sheet.
 18. The method of claim 17, further comprising, prior to attaching the moisture absorbing device to the second surface of the food container, removing the removable sheet from the attaching layer.
 19. The method of claim 16, wherein the device further comprises a removeable liner covering the first surface of the carrier layer, wherein the first surface of the carrier layer is exposed to the moisture inside of the food container upon removal of the removeable liner; and wherein the method further comprising, prior to closing the food container, removing the removeable liner from the carrier layer.
 20. A method of preparing a moisture absorbing device, comprising: a carrier layer having a first surface and a second surface separated from the first surface by a first spaced distance, wherein the first spaced distance defines a thickness of the carrier layer; an absorbent layer having a third surface in continuous contact with the second surface of the carrier layer, and a fourth surface separated from the third surface by a second spaced distance, wherein the second spaced distance defines a thickness of the absorbent layer; wherein the absorbent layer comprises a hydrogel composition; and an attaching layer having a seventh surface in non-continuous contact with the sixth surface of the ventilation layer and an eighth surface separated by a fourth spaced distance from the seventh surface, wherein the fourth spaced distance defines a thickness of the attaching layer; wherein the attaching layer comprises an adhesive material on the eighth surface for attaching the device to a surface of the food container; the method comprising a roll-to-roll assembly of the device, including: providing the carrier layer, depositing the absorbent layer onto the second surface of the carrier layer; adhering fifth surface of the ventilation layer to the fourth surface of the absorbent layer; adhering seventh surface of the attaching layer to the sixth surface of the ventilation layer; and adhering the eight surface of the attaching layer to an interior surface of a food container. 